Control system bypassing for industrial cold storage

ABSTRACT

Some embodiments include a control bypass system for industrial cold storage facilities. In some embodiments, the control bypass system includes a cloud scheduler and a bypass controller. The cloud scheduler may be located in a remote location. The cloud scheduler may create a power draw prescription for one or more items of cold storage equipment at the industrial cold storage facility. The power draw prescription, for example, can include a desired power draw level for one or more items of cold storage equipment at the industrial cold storage facility and the desired power draw level changes over a period of time. The bypass controller can be located at the industrial cold storage facility and receives the power draw prescription from the cloud scheduler, produces an environmental setpoint for the one or more items of equipment, and outputs the environmental setpoint to a device or system controller.

BACKGROUND

A successful control system may have sufficient sensor data as well asdirect control over the equipment it is meant to control. There aresituations, however, in which it is not possible to directly set theoutput of a controller (e.g., the speed of an electric motor, theposition of a valve, the electrical current through a heater, the flowrate of a pump, etc.). There are a number of scenarios where directcontrol may not be possible. For example, an existing control system mayalready have been installed and may offer the only feasible interfacethrough which to communicate desired actions to the equipment. Inaddition, a cold storage facility may be able to sense and controlenvironmental parameters within the cold storage facility.

SUMMARY

Some embodiments include a system comprising: a cloud scheduler locatedin a remote location; and a bypass controller that receives power drawprofiles from the cloud scheduler and outputs environmental setpoints toa device or system controller.

Some embodiments include a method comprising: receiving a power drawprescription from a cloud scheduler; converting the power drawprescription to a temperature setpoint; and communicating thetemperature setpoint to a device or system controller.

These illustrative embodiments are mentioned not to limit or define thedisclosure, but to provide examples to aid understanding thereof.Additional embodiments are discussed in the Detailed Description, andfurther description is provided there. Advantages offered by one or moreof the various embodiments may be further understood by examining thisspecification or by practicing one or more embodiments presented.

Some embodiments include a control bypass system for industrial coldstorage facilities. In some embodiments, the control bypass systemincludes a cloud scheduler and a bypass controller. The cloud schedulermay be located in a remote location. The cloud scheduler may create apower draw prescription for one or more items of cold storage equipmentat the industrial cold storage facility. The power draw prescription,for example, can include a desired power draw level for one or moreitems of cold storage equipment at the industrial cold storage facilityand the desired power draw level changes over a period of time. Thebypass controller can be located at the industrial cold storage facilityand receives the power draw prescription from the cloud scheduler,produces an environmental setpoint for the one or more items ofequipment, and outputs the environmental setpoint to a device or systemcontroller. In some embodiments, the system controller comprises a PIDcontroller.

Some embodiments may include a method comprising: receiving, at a bypasscontroller at an industrial cold storage facility, a power drawprescription from a remote server, the power draw prescription includesa desired power draw level for one or more items of cold storageequipment at the industrial cold storage facility, and the desired powerdraw level changes over a period of time; converting, at the bypasscontroller, the power draw prescription to a temperature setpoint for aportion of the cold storage facility based on a mathematical model ofthe one or more items of cold storage equipment; and communicating thetemperature setpoint to a cold storage facility system controller thatis coupled with the one or more items of cold storage equipment.

In some embodiments, the one or more items of cold storage equipmentcomprises one or more of a motor, a valve, a vessel, an evaporator, acondenser, a pump, a compressor, a door, an underfloor heating element,a light, defrost equipment, a centrifuge, and/or a furnace.

In some embodiments, the method may also include: receiving, at thebypass controller, temperature data from a temperature sensor at theportion of the cold storage facility; determining, at the bypasscontroller, whether the temperature data has exceeded or is approachinga threshold temperature value for the portion of the cold storagefacility; and in the event the temperature data has exceeded or isapproaching a threshold temperature value: producing a secondtemperature setpoint; and communicating the second temperature setpointto the system controller.

Some embodiments include a bypass controller. The bypass controller maybe in communication with a cloud controller and a device controller atan industrial cold storage facility. The bypass controller may include atransceiver that receives data from a cloud scheduler located in alocation remote from the industrial cold storage facility and aprocessor. The processor may receive a power draw prescription for oneor more items of cold storage equipment at the industrial cold storagefacility, the power draw prescription includes a desired power drawlevel for one or more items of cold storage equipment at the industrialcold storage facility, and the desired power draw level changes over aperiod of time. The processor may produce an environmental setpoint forthe one or more items of equipment. The processor may output theenvironmental setpoint to a device controller or a system controller.

In some embodiments, the processor may output the environmental setpointvia the transceiver. In some embodiments, the processor may output theenvironmental setpoint via an output that is separate and distinct fromthe transceiver.

BRIEF DESCRIPTION OF THE FIGURES

These and other features, aspects, and advantages of the presentdisclosure are better understood when the following Detailed Descriptionis read with reference to the accompanying drawings.

FIG. 1 is a block diagram of an industrial facility control systemaccording to some embodiments.

FIG. 2 is a block diagram of a direct expansion single stagevapor-compression refrigeration system according to some embodiments.

FIG. 3 is an example schematic of an existing PID control system.

FIG. 4 is an example schematic of a PID control system according to someembodiments.

FIG. 5 is an example schematic of a PID control system according to someembodiments.

FIG. 6 is an example schematic of a PID control system according to someembodiments.

FIG. 7A is a plot of temperature and FIG. 7B is a plot of power during adefrost cycles for systems with and without the bypass controller.

FIG. 8A is a plot of the power draw and FIG. 8B is a plot of thetemperature of a refrigerator when the refrigerator is used as a thermalbattery without control system bypassing according to some embodiments.

FIG. 9A is a plot of the power draw and FIG. 9B is a plot of thetemperature of a refrigerator when the refrigerator is used as a thermalbattery with control system bypassing according to some embodiments.

FIG. 10 is a flowchart of a process for bypass control system accordingto some embodiments.

FIG. 11 is a flowchart of a process for bypass control system accordingto some embodiments.

FIG. 12 shows an illustrative computational system for performingfunctionality to facilitate implementation of embodiments describedherein.

DETAILED DESCRIPTION

In some embodiments, a successful control system may have sufficientenvironmental sensor data as well as direct control over the equipmentit is meant to control. There are situations, however, in which it isnot possible to directly set the output of a controller (e.g., the speedof an electric motor, the position of a valve, the electrical currentthrough a heater, the flow rate of a pump, etc.). There are a number ofscenarios where direct control may not be possible such as, for example,an existing control system has already been installed and offers theonly feasible interface through which to communicate desired actions tothe equipment. This may include, for example, interfacing with anexisting control system may only allow push setpoints (e.g. temperature,pressure, etc.) rather than giving direct control over the output (e.g.motor speed, valve position, applied voltage, etc.).

As another example, some means of changing the state of equipment maynot directly set the state, but may set the rate of change of the state.This may include, for example, a slide valve whose position iscontrolled by turning a rack and pinion mechanism (or a hydraulicactuated valve) to gradually increase or decrease the valve opening,which may set the rate of change of pressure within the vessel. In thiscase, a control action only directly affects the rate at which the valveopens, not the position of the valve itself.

As yet another example, some equipment maybe controlled by an equipmentcontroller or a facility controller. These controllers may receive anenvironmental setpoint (e.g., temperature, pressure, humidity, etc.) andcontrol the equipment based on an environmental setpoint. However, thesecontrollers may not be able to control the equipment based on the poweror energy requirements. And, for example, may not be able to do so whileensuring certain environmental parameters are maintained withinappropriate thresholds.

FIG. 1 is a block diagram of an industrial facility control system 100according to some embodiments such as, for example, as an industrialcold storage facility. In some embodiments, the industrial facilitycontrol system 100 includes a scheduler 105. The scheduler 105 may be acloud-based computing system (e.g., Amazon Web Services, Google Cloud,Microsoft Azure, IBM Cloud, etc.) or a local computing system that canuse various predictive techniques, which may be based on the state ofthe facility as determined based on data from various sensors within anindustrial facility 110, to control various controllable devices, whichmay occur through an onsite facility coordinator or may occur directlyfrom the cloud scheduler or both. In some embodiments, the scheduler 105may include various algorithms that can be used to optimize the energyuse according to various metrics such as, for example, based upon energyusage within the industrial facility 110.

In some embodiments, the industrial facility control system 100 includesan industrial facility 110 and a scheduler 105. The industrial facility110 may include any type of facility that may include various subsystemsand/or systems. For example, the industrial facility 110 may be a coldstorage facility, a factory, a farm, a packing house, a dairy, a growfacility, a hydroponic facility, a warehouse, a distribution center, acement manufacturing facility, oil and gas processing facilities, watertreatment plants, oil refineries, petrochemical processing facilities,chemical processing facilities, natural gas processing facilities, cropirrigation, water districts, desalinization, etc.

In some embodiments, the industrial facility control system 100 mayinclude a facility coordinator 115. The facility coordinator 115 may bein communication with the scheduler 105 via any network connection. Insome embodiments, the network connection may be a wired connection suchas, for example, via the Internet. In some embodiments, thecommunication channel between the facility coordinator 115 and thescheduler 105 may be initiated via a request from the facilitycoordinator 115. In some embodiments, the network connection may be awireless connection such as, for example, a 4G or 5G network (orsimilar), an LTE network, a satellite network, etc.

In some embodiments, the industrial facility 110 may include any numberof controllable devices such as, for example, motors 120 (e.g., fans,turbines, etc.), valves 125, vessels, evaporators, condensers, pumps,compressors, doors, underfloor heating elements, lighting, defrostequipment, centrifuges, furnaces, etc. In some embodiments, thecontrollable devices may be controlled by a device controller thatinterfaces with the facility coordinator 115. For example, a vessel maybe controlled by a vessel controller 130; an evaporator may becontrolled by an evaporator controller 135; a condenser may becontrolled by a condenser controller 140; a pump may be controlled by apump controller 145, a channel gate controller 150, valves may becontrolled by a valve controller, and heaters/heating elements may becontrolled by heater/heating element controllers, or an any othercontrollable device or controller. In some embodiments, thesecontrollers may be coupled with the facility coordinator 115, may beintegrated with the controllable device, and/or may or may not bedesigned by the manufacturer of the controllable device.

In some embodiments, the facility coordinator 115 may be incommunication with each of the controllable devices and may providecommands to the various controllable devices.

In some embodiments, the industrial facility 110 may include any numberof sensors such as, for example, a temperature sensor 170, a vesselpressure sensor 175, a condenser pressure sensor 180, a compressor oilpressure sensor 185, vessel level sensor 190, a humidity sensor, a fanspeed sensor, a voltage sensor, or anemometer, flow meter, microphone,vibration sensor, pH meter, optical density meter, chemicalconcentration sensors, or any other sensor 195. The sensor may includeany type of transducer that can translate physical properties into anelectrical signal (either an analog or digital signal) that can becommunicated to the facility coordinator 115 via a wired or wirelesscommunication network. In some embodiments, the sensors may include anytype of Internet of Things (IoT) device that can measure physicalproperties and communicate these properties to a network database suchas, for example, at the facility coordinator 115.

In some embodiments, an industrial facility 110 may be a cold storagefacility that may include any number of buildings. In some embodiments,an industrial facility 110 may include one or more cold storagebuildings that use a vapor-compression refrigeration system to cool oneor more rooms within the cold storage facility.

A block diagram of an example refrigeration system 200 is shown in FIG.2. The refrigeration system 200 may include one or more compressors 205,one or more condensers 210, vessel 215 one or more expansion valves 220,one or more evaporators 230, a plurality of evaporator fans 225, and aplurality of condenser fans 240. In some embodiments, the condenser 210may include the plurality of condenser fans 240. In some embodiments,the evaporate may include the plurality of evaporator fans 225. Thevessel 215, while shown graphically as two vessels, may be a singlevessel. In some embodiments, the vessel 215 may enclose the refrigerantin both vapor and liquid states. The liquid level within the vessel 215may be vary based on various parameters.

In some embodiments, a circulating liquid refrigerant can be used in therefrigeration system 200 as the medium which absorbs and removes heatfrom a space to be cooled within the industrial facility 110 andsubsequently rejects that heat elsewhere. The refrigeration system 200may include a compressor 205, a condenser 210, a thermal expansion valve220 (e.g., which also may be called a throttle valve or metering valve),an evaporator 230, or a vessel 215. The circulating refrigerant canenter the compressor 205 from the vessel 215 in the thermodynamic stateknown as a vapor (e.g., saturated vapor or non-saturated vapor) and iscompressed to a higher pressure, resulting in a higher temperature aswell. The hot, compressed vapor can then be in the thermodynamic stateknown as a superheated vapor and is at a temperature and pressure atwhich it can be condensed with either cooling water or cooling airflowing across coils or tubes in the condenser 210. This is where thecirculating refrigerant can reject heat from the system. The rejectedheat can be carried away by either the water or the air (whichever maybe the case). The condenser fans 240, for example, can blow air acrossthe condenser 210, which may warm the air carrying away the heat.

The condensed liquid refrigerant, in the thermodynamic state known as asaturated liquid, can then be returned to and held in vessel 215. Theliquid refrigerant may then be routed through an expansion valve 220where it undergoes an abrupt reduction in pressure. That pressurereduction may result in the adiabatic flash evaporation of a part of theliquid refrigerant. The auto-refrigeration effect of the adiabatic flashevaporation can lower the temperature of the liquid and vaporrefrigerant mixture to where it is colder than the temperature of theenclosed space to be refrigerated; this may occur within the evaporator230.

The cold mixture can be routed through coils or tubes in the evaporator230. One or more evaporator fans 225 can circulate the warm air in theenclosed space across the coil or tubes carrying the cold refrigerantliquid and vapor mixture. That warm air evaporates the liquid part ofthe cold refrigerant mixture. At the same time, the circulating air iscooled and thus lowers the temperature of the enclosed space. Theevaporator 230 is where the circulating refrigerant absorbs and removesheat which is subsequently rejected in the condenser 210 and transferredelsewhere by the water or air used in the condenser 210.

To complete the refrigeration cycle, the refrigerant vapor from theevaporator 230 is again a saturated vapor and is routed back into thecompressor 205.

In some embodiments, the facility coordinator 115 may receive sensordata from one or more sensors. In some embodiments, the sensor data maybe stored at the facility coordinator 115. In some embodiments, thesensor data may be communicated to the scheduler 105 and/or stored in adatabase in the cloud scheduler. In some embodiments, the sensor datamay be stored at the facility coordinator 115 and communicated to thescheduler 105 on a predetermined cadence such as, for example, everyminute, every few minutes, every 15 minutes, every hour, every day,every week, or every month. In some embodiments, the facilitycoordinator 115 may also communicate information such as the activeprescription, corrective action applied, modifications to aprescription, etc. In some embodiments, the facility coordinator 115 mayapply some corrective action based on the sensor data.

To control the facility, in some embodiments, the facility coordinator115 may receive one or more prescriptions from the scheduler 105. Aprescription may include one or more environmental, power or energy,process, or facility setpoints to be conducted or achieved by thefacility coordinator 115. A prescription may be time varying and/orchange over time. In some embodiments, the facility coordinator 115 maytranslate a prescription to achieve an environmental setpoint based onthe specific devices, equipment, environment, controllers, etc. locatedwithin the industrial facility 110. In some embodiments, the facilitycoordinator 115 may receive abstract or broad facility prescriptions andtranslate these prescriptions into a translated prescription that may,for example, include actionable or specific commands, which may bemanifested by changing environmental setpoints to equipment controllersand/or higher level control systems, individual device actuator signals,etc., and/or some combination thereof, and which can be implemented,applied, or executed within a specific facility. The facilitycoordinator 115 may translate a prescription from the scheduler 105 intoa prescription that is actionable at the specific industrial facility110 based on the various constraints and equipment at the specificindustrial facility 110. In some embodiments, the scheduler 105 mayperform some translation of the prescriptions prior to transmission tothe facility coordinator 115.

In some embodiments, a prescription may be provided by the scheduler 105to attempt to optimize energy use within the industrial facility 110.For example, a prescription may include an energy or a temperaturesetpoint for a specific industrial facility 110 and/or components orportions of the industrial facility 110 such as, for example, one ormore rooms or one or more blast cells; a fan speed setpoint for one ormore fans; a vessel pressure setpoint or a vessel level setpoint for oneor more vessels, a compressor energy usage setpoint or a compressorspeed setpoint for one or more compressors; a defrost time period orschedule, a duration of defrost sub events within a defrost event, acondenser pressure setpoint for one or more compressors, an irrigationchannel gate position setpoint, a water pump power setpoint or a waterpump speed setpoint for one or more water pumps, an irrigation linevalve setpoint for one or more irrigation line valves, a fertilizer feedrate, a flow rate setpoint for one or water pumps, an industrialagitator motor speed setpoint for one or more motors, or a turbine speedsetpoint, etc.

In some embodiments, the facility coordinator can include all or aportion of the components of the computational system 1100 shown in FIG.11.

In addition, in some embodiments, the facility coordinator 115 mayreceive one or more equipment constraints, operational constraints, orenvironmental constraints (collectively or individually “constraints”)from the scheduler 105 or have one or more equipment constraints,operational constraints, or environmental constraints hard coded withinthe facility coordinator 115. The facility coordinator 115 may receiveone or more constraints from the scheduler 105 at a given time andupdate the constraint at the facility coordinator 115. In someembodiments, constraints may be hard-coded within a given equipment ordevice, or hard-coded within the facility coordinator 115. In someembodiments, certain hard-coded constraints may not be modifiableremotely.

An equipment constraint, for example, may include a maximum vesselpressure, a minimum vessel pressure, a maximum vessel level, a minimumvessel level, a maximum compressor oil temperature, maximum compressorintake pressure, minimum compressor discharge pressure, minimum runningcompressor speed, a maximum condenser pressure, a maximum fan speed, aminimum running fan speed, etc. Any of the equipment constraints, forexample, may be a function of operational, environmental, and otherequipment states.

An environmental constraint, for example, may include a maximumtemperature, a minimum temperature, a maximum humidity, a minimumhumidity, maximum pressure, minimum pressure, lights on/off, etc. Insome embodiments, an environmental constraint may be specific to afacility, a subsection of a facility, or a given room within a facility.In some embodiments, an environmental constraint may depend on aproduct, a product family, or a product type.

An operational constraint, for example, may include any type ofconstraint related to operations, or constraints that are notenvironmental constraints or equipment constraints. An operationalconstraint, for example, may include a constraint to periodicallydefrost certain pipes, lower the fan speeds during certain hours, loweror turn off the fans when a door is open or within a time period ofbeing opened, quickly freeze certain items within a certain period oftime, lights on time, lights off time, etc. The operational constraints,for example, may include time-based constraints.

In some embodiments, the constraints may be hierarchical. For example, atemperature constraint may override a constraint that limits the timeperiod when fans are running. As another example, a vessel pressureconstraint may override a fan speed constraint. As another example, anequipment constraint may override an operational constraint. As anotherexample, an equipment maintenance schedule constraint may take precedentor have priority over a cooling power constraint. Constraints may take ahierarchy of priority, including immutable properties of a piece ofequipment (e.g., a fan speed is bound by zero and its max rpm, the levelof a vessel is bound by zero and the height of the vessel, etc.),environmental constraints (e.g., room temperature, humidity, etc.), andprescribed constraints (e.g., the scheduler prescribing a fan speed,cooling power, etc.). In all cases, a prescribed constraint has thelowest priority. As an example, a room temperature operationalconstraint may override an evaporator fan speed prescription/coolingpower draw prescription. An as another example, a vessel pressure safetyconstraint may override an environmental constraint such as, forexample, a room temperature setpoint. Various other hierarchies may bedefined and followed.

In some embodiments, a facility coordinator 115 or a scheduler 105 mayprovide rapid prototyping and real-time data analysis via cloud accessto all sensor or process data. In some embodiments, custom userprivilege levels can be set at the application level to ensure safe andsecure cloud access. In some embodiments, secure buffering protocols maybe used to ensure synchronization between the facility coordinator andthe scheduler 105.

In some embodiments, a facility coordinator 115 or a scheduler 105 mayimplement hierarchical set-points, set-point inequalities, or set-pointranges to safely control individual components, controllable devices, orsensors. For example, an energy strategy may request a specific speedfor an evaporator fan, but the control system must override this requestif freezer temperatures reach a user-defined limit.

In some embodiments, virtual sensors may be used. In some embodiments, auser can define the composition of multiple physical sensors or externaldata to create a virtual sensor. A virtual sensor, for example, can beused in any scenario in which a physical sensor can be used, such astriggering alerts or controlling system processes. For example, suctionpressure, discharge pressure and compressor power may be transformed(e.g., using a mathematical transformation) to create a virtual sensorthat represents the thermal power and efficiency of the compressor. Insome embodiments, the cooling efficiency may include the thermal work(e.g., heat absorbed by the evaporators) relative to electrical workover a period of time. Another virtual sensor, for example, may describethe cooling power (e.g., the heat removed) provided by a givenevaporator or set of evaporators via a mathematical transformation basedon a model that is a function of evaporator fan speed, air temperature,evaporator coil temperature, coolant flow rate through the evaporator,relevant equipment properties, or coolant properties, or other relevantphysical properties. An alert, for example, can be created to notifyoperations when compressors are underperforming and need maintenance.

In some embodiments, multi-input and/or multi-output process control canbe implemented at the facility coordinator. For example, a user candefine a custom control process which combines multiple sensors (e.g.,including virtual sensors) to control multiple outputs via user definedcontrol methods such as PIDs and deadbands. For example, a customcontrol process can set facility electrical load by combining sensorsthroughout the plant and dynamically adjusting multiple components ofthe refrigeration system simultaneously.

An example schematic of an existing control system is shown in the FIG.3. In this example, a desired setpoint y* (e.g. temperature, humidity,etc.) is given, and fed into the existing PID controller 305(proportional-integral-derivative controller), along with the output yfrom a physical system 310. The PID controller 305 may perform amathematical operation on the setpoint y* and the physical system outputy, and produces control variable u, which is the effort to be applied tothe system.

This policy is effective in theory, assuming that the existing controlsystem does a good job ensuring that the output y matches the desiredsetpoint y*. There are a number of situations where this policy may besubpar. For example, the PID controller 305 may be subpar when theexisting control system simply is not tuned well, and therefore does apoor job of matching output y to setpoint y* (e.g. output y oscillatesaggressively whenever the setpoint is changed). As another example, aPID controller 305 may be subpar when one desires not a y setpoint, butrather a control variable u setpoint, for example, that is, one wishesto directly manipulate the control effort or other state of the systemrather than the system output y.

Some embodiments described in this disclosure may manipulate thesetpoint of an existing controller to produce the desired results.

FIG. 4 is an example schematic of a PID controller 305 according to someembodiments. The goal may be to set the system to setpoint y* with a PIDcontroller 305 that controls control variable u. The PID controller 305may be considered inverted, for example, as shown in dashed line 405. Anexternal controller, for example, can mathematically infer setpoint y*from variable u* by reversing the operation inside the PID controller305. This may, for example, require an assumption about the output y(e.g. that it is constant, linear, etc.).

In some embodiments, the system model physics may be inverted (e.g.,line 410). The PID dynamics, for example, may also be converted. In someembodiments, a setpoint can be set first by the PID controller 305,which may try to get the output y as close as possible. In this example,the temperature is not controlled the control variable u (e.g., thecontrol effort) is controlled. Rather than infer an effort (e.g.,variable u) to get to a setpoint, a temperature can be inferred to getan effort. An external controller, for example, can mathematically infersetpoint y* from variable u* by simulating the system using aquantitative physics model. This may, for example, require making theassumption that the existing PID is ideal (so that setpoint y*=setpointy).

In some embodiments, a controller may choose to switch between thestrategy of reversing the PID operation and reversing the physics model.

FIG. 5 is an example schematic of a PID control system 500 according tosome embodiments. In this example, a control system 505 may be coupledwith the PID controller 305 and may receive feedback from the output ofthe PID controller 305: control variable u. The control system 505 caninput setpoint u* and control variable u. In some embodiments, thecontrol system 505 may be a PID controller, a model predictivecontroller, or another controller.

In some embodiments, this example may include a combination of theexamples shown in FIG. 4 and/or FIG. 3 For example, the PID controlsystem 500 can be, for example, a model predictive control (MPC) usingeither the existing PID controller 305 (to implement DIP), or the systemmodel physics (to implement PMS), making the appropriate assumptionsmentioned above.

In some embodiments, the control system 505 can include an MPC, treatingits model as the combined system-PID model. In this example, theexisting control system may be a PID control system.

FIG. 6 is an example schematic of a bypass control system 600 accordingto some embodiments. The cloud scheduler 605 may include the scheduler105. The bypass controller 610 (e.g., an ATLAS controller) may includefacility controller 115 or the control system 505. The existing controlsystem 615 may include all or a subset of the devices and/or controllersof an industrial facility 110.

Three control loops are shown. The control loop 625, for example, may bean existing PID control loop such as, for example, as shown in FIG. 3.The control loop 625, for example, may be a responsive control loop. Inthe control loop 625, for example, the existing controller may outputvoltage signals and input environmental signals (e.g., temperature,pressure, motor speed, etc.) from a sensor.

The control loop 630, for example, may be the control loop 630 shown inFIG. 5. In the control loop 630, for example, the bypass controller 610(e.g., an ATLAS controller) may setpoint input environmental signals(e.g., temperature, pressure, motor speed, etc.) from a sensor and/oroutput a temperature setpoint. The control loop 630, for example, may beless responsive than the control loop 625, but more responsive than thecontrol loop 635.

The control loop 635 may execute on a server in the cloud or on a localserver. The control loop 635, for example, may be slow to respond, mayinclude various power optimizations, and/or may operate on complexmodels. In the control loop 635, for example, the cloud scheduler 605may output power draw data or signals, and/or input environmentalsignals (e.g., temperature, pressure, motor speed, etc.) from a sensor.

In some embodiments, an optimized power draw schedule can be computed bythe cloud scheduler 605, which may be a local or cloud-based server. Aprescription can be passed down to the bypass controller 610, which canconvert the power draw into a temperature setpoint which the existingcontrol system 615 can accept via one of the methods described above.The bypass controller 610, for example, may push this temperaturesetpoint to the existing control system 615, which may reside, forexample, on an existing controller at a facility. The existing controlsystem 615, for example, may then output a voltage signal to equipmentwithin the facility, which may alert its state, and has the effect ofdrawing a possibly different amount of electrical current. In themeantime, the control loop 625, which is not within the direct controlof either the bypass controller 610 or the cloud scheduler 605, maycontinue to run to match the temperature setpoint which was provided bythe bypass controller 610.

In some embodiments, if the model being used by the bypass controller610 is accurate, then the resulting power draw will match theprescription power draw passed down from the cloud scheduler 605 to thebypass controller 610. Any disturbances in the equipment that mightcause deviations between the predicted state trajectory and the actualtrajectory may manifest as differences in the feedback signals, whichthe bypass controller 610 may read and compare to its internal model todetermine how it needs to change its temperature setpoint to maintainthe power draw equal to the power draw setpoint.

In some embodiments, the control loop 630 may be used to reduce powerspikes in an industrial refrigeration system (e.g., as shown in FIG. 2).These power spikes, for example, may be used to handle randomdisturbances from opening of refrigerator doors by bypassingdisturbances to room temperature.

In some embodiments, the cloud scheduler 605 can send the bypasscontroller 610 a power draw setpoint. The bypass controller 610 candetermine the optimal cooling schedule for a refrigerator based on thepower draw setpoint to maintain temperature bounds using any type ofmathematical model (e.g., a quantitative thermal model). When the bypasscontroller 610 pushes the corresponding optimal temperature setpointschedule to the existing control system 615, any thermal disturbance(e.g., from unforeseen effects like heat flux through doors) will causethe control loop 635 to crank the refrigerators to match the temperaturesetpoint. This situation may not match the model at the bypasscontroller 610, since the temperature bounds are wide enough toaccommodate these fluctuations, and doing so will remove the electricaldemand spike that would be required if the temperature setpoint were tobe followed in a conformist manner.

In some embodiments, the cloud scheduler 605 may push an electrical drawschedule, which can only be applied by virtual control in a situationwhere the refrigerator already has an immutable control systeminstalled. This electrical draw schedule may be passed to the bypasscontroller 610, which determines a temperature setpoint schedule tobegin applying to the system in order to effect the desired electricaldraw schedule and sends the temperature setpoint to the existing controlsystem 615.

In some embodiments, the bypass control system can be used to reducepower spikes in an industrial refrigeration system due to randomdisturbances from opening of refrigerator doors by bypassingdisturbances to low pressure receiver (LPR) pressure and/or level.

In some embodiments, the cloud scheduler 605 can determine the optimalcooling schedule for a refrigerator by considering how much electricitymay be used to maintain bounds using a mathematical model such as, forexample, a quantitative thermal model. When the bypass controller 610pushes the corresponding optimal pressure setpoint schedule to theexisting control system 615, any thermal disturbance (from unforeseeneffects like heat flux through doors, expansion valves opening,defrosts, etc.) may cause the control loop 625 to crank the compressorto maintain the vessel pressure/level setpoints. This situation is notwhat the scheduler had in mind, since the pressure/level bounds are wideenough to accommodate these fluctuations, and doing so will remove theelectrical demand spike that would be required if the setpoints were tobe followed in a conformist manner.

In some embodiments, the cloud scheduler, can provide the bypasscontroller 610 an electrical draw schedule. The bypass controller 610may determine a pressure/level setpoint schedule to send to the existingcontrol system 615 to apply to the system in order to effect the desiredelectrical draw schedule.

FIG. 7A is a plot of temperature and FIG. 7B is a plot of power during adefrost cycles for systems with and without the bypass controller 610.In the upper plot (without the bypass controller 610), whenever adefrost event occurs (e.g., an unexpected defrost event) the existingcontrol system 615 can detect that the room temperature is higher thanthe temperature setpoint (e.g., the setpoint line 715). The defrostevent may be any event that injects a great deal of heat into the systemto melt ice on the evaporator. For example, the existing controller maysense the change in temperature and blasts the refrigerators to attemptto compensate and bring the temperature to the setpoint.

In the lower plot, with the bypass controller 610, the increase intemperature is accepted so long as it is below a maximum temperature. Inresponse, the system may not attempt to immediately drive thetemperature back to the temperature setpoint 715 and not causing a powerdraw spike associated with bringing the temperature back down to thesetpoint. In this example, the temperature stays in bounds and the powerdraw is lowered. In some embodiments, if the temperature within therefrigerator approaches or exceeds T_(max) the bypass controller 610 mayrequire the existing controller to turn on the cooler to ensure thetemperature stays within bounds.

FIG. 8A is a plot of the power draw and FIG. 8B is a plot of thetemperature of a refrigerator when the refrigerator is used as a thermalbattery without control system bypassing according to some embodiments.In some embodiments, unexpected heat flux into afreezer/cooler/refrigerator can be mitigated by using the roomtemperature as a thermal battery.

In some embodiments, a freezer/cooler/refrigerator can operate under anoptimized control schedule to minimize utility charges due to highenergy usage and/or high energy prices during specific times of the dayThese specific times can include any time period such as, for example,between 12 PM to 5 PM.

In some embodiments, the system may determine that the price forelectricity between certain hours (e.g., the hours of 12 PM and 5 PM) isvery high (or any other time period as determined by the system or inputby a user). An optimal schedule can be determined based on typicaloperation of the refrigerator, which is showed by line 805 in FIG. 8A.The schedule provided by the cloud scheduler may prescribe more power torun the refrigerator during inexpensive times, and less power duringexpensive times. The cloud scheduler may calculate this based onknowledge that the freezer temperature can maintain within allowablebounds (shown as black dashed lines) such as, for example, between about20° F. and 0° F., which it can compute using the mathematical model ofthe freezer. In some embodiments, the cloud scheduler may not have theability to control the freezer power draw directly, and instead only hascontrol over the temperature setpoint, shown in line 815 in FIG. 8B.

In order to consume the desired utility power, for example, amathematical model of the freezer physics can be used to relate thepower consumed to the resulting freezer temperature as a function oftime. The result is, assuming the model is a good representation of thereal-world physics, the refrigerator consumes the desired amount ofpower from the utility. However, no model is 100% accurate, so there maybe discrepancies between the temperature setpoint, and the actualfreezer temperature (line 820 in FIG. 8B), and consequently differencesin the scheduled power draw and the actual power draw (line 810 in FIG.8A). In this example, the source of discrepancy between the model andthe real-world reality is that an unforeseen heat flux occurred, whichmay cause the actual freezer temperature to rise considerably. Since thefreezer runs on a temperature control system, this temperature increasecauses a corresponding increase in the actual power drawn from theutility as shown in line 810 in FIG. 8A. This is unacceptable, sincethis increase in power draw is untimely and will cost us greatly.

In some embodiments, a control bypass system can compensate for this byforming a relationship between the temperature and power draw using thecontrol system model, rather than using the physical model (which may beprone to unforeseen disturbances). With Control System Bypassing,instead of scheduling a temperature setpoint schedule ahead-of-time, thedesired power draw (or any other parameter) may be scheduledahead-of-time instead, and one of the methods described earlier in thisdocument works to command an appropriate temperature setpoint in orderto bring about the desired amount of power draw from the freezer system.

In some embodiments, a disturbance 825 may create a non-negotiablechange in the physics, which will either impact the power draw, thetemperature, or both. In some embodiments, control system bypassing maychoose which of these outcomes is most favorable. The following figureshows the same graphs as before, but with control system bypassing. Inthis example, when the unforeseen heat flux occurs (disturbance), theeffects of that disturbance are absorbed entirely into warming thefreezer, rather than drawing more power from the utility during theexpensive time window.

FIG. 9A is a plot of the power draw and FIG. 9B is a plot of thetemperature of a refrigerator when the refrigerator (or cooler) is usedwith control system bypassing according to some embodiments. Therefrigerator may, for example, act as a thermal battery.

In some embodiments, the cloud scheduler may compute an optimizedschedule assuming an idealized model that has a lower power draw duringtimes with high utility prices. The resultant power draw is reduceddramatically during the expensive portion of the day. For example,during this time, the compressor may draw power to reduce the pressureof the vessel when necessary, and it may do so by running a controlsystem on the vessel pressure. In some embodiments, to produce thedesired utility power draw, the cloud controller may use a mathematicalmodel to determine the physical relationship between the pressure of thevessel and the requisite compressor power draw, and then push thatpressure setpoint schedule to the control system to try to match theactual power draw to the desired power draw.

In some embodiments, an unexpected disturbance may come about, causingthe pressure in the vessel to increase more than expected by the model.When this happens, the vessel pressure may rise, and the control systemmat kick on the compressor to compensate, which may use utility powerduring the expensive part of the day. With control system bypassing, forexample, a desired power draw schedule may be determined as before, butthe model of the control system (rather than the physics of the vesselpressure and condenser) can be used to relate the pressure setpoint tothe power draw used by the compressor. The relevant figures lookidentical to the two previous figures, except the temperature axis isreplaced with pressure.

As shown in FIG. 9B, the temperature 815 remains within the refrigeratoris kept within the temperature thresholds.

FIG. 10 is a flowchart of a process 1100 for bypass control systemaccording to some embodiments. The process 1000 may include additionalblocks, some blocks may be skipped or may not be used, and/or the blocksmay occur in any order.

Process 1000 begins at block 1005. The bypass control system (e.g.,facility coordinator 115) may receive a power draw prescription. Thepower draw prescription, for example, may be received from a remoteserver such as, for example, from scheduler 105. The power drawprescription, for example, may include a power level for one or moreitems of equipment in a facility such as, for example, a cold storagefacility. The power draw prescription, for example, may include a powerprofile that varies over time. The power draw prescription, for example,may include a power profile that is lower during times of high energydemand and/or high energy prices. The power draw prescription, forexample, may include a power profile that is higher during times of lowpower demand and/or low energy prices. The power draw prescription, forexample, may apply to all the items of equipment at a facility, a subsetof items of equipment, or one item of equipment at a facility.

At block 1010, the process 1000 determines or creates an environmentalsetpoint for one or more items of equipment based on the powerprescription. The environmental setpoint, for example, may include atemperature setpoint, a humidity setpoint, a pressure setpoint, etc. Theenvironmental setpoint, for example, may not include energy setpoint ora power setpoint. The environmental setpoint may, for example, include atemperature setpoint for a cooler. The temperature of the cooler, forexample, may be controlled by a number of different items of equipment.The environmental setpoint may be created based on various models of theitems of equipment and/or the facility that relate environmentalparameters with power consumption.

At block 1015 the environmental setpoint can be sent to a cold storagefacility system controller and/or one or more items of equipment. Thecold storage facility system controller, for example, may include a PIDcontroller or a similar controller. The cold storage facility systemcontroller, for example, may include one or more of a vessel controller130, an evaporator controller 135, a condenser controller 140, a pumpcontroller 145, and/or a channel gate controller 150, etc. The coldstorage facility system controller, for example, may include a coolercontroller.

At block 1020 environmental parameters within the cold storage facilityand/or one or more of the items of equipment may be measured from one ormore sensors. These sensors may include a temperature sensor 170, avessel pressure sensor 175, a condenser pressure sensor 180, acompressor oil pressure sensor 185, a vessel level sensor 190, and/orother sensor 195.

In some embodiments, the sensor data and/or actual power consumptiondata may be used to update the model used by the bypass controller torevise the model used in block 1010 to create the environmental setpointfrom a power draw prescription. An updated model may be created and/orupdated at the bypass controller and/or the cloud controller.

At block 1025, if the bypass controller or the cold storage facilitysystem controller determines the environmental parameter is not belowthe upper threshold value or above the lower threshold value, theprocess 1000 may proceed to block 1030. If the bypass controller or thecold storage facility system controller determines the measuredenvironmental data is above or near the upper threshold and/or below ornear the lower threshold the process 1000 may proceed to block 1040 Insome embodiments, a single threshold may be used such as, for example,an upper temperature threshold.

For example, the upper threshold for a temperature threshold may beabout 0° C. and the lower threshold for a temperature threshold may beabout −20° C. As another example, the upper threshold for a temperaturethreshold may be about −5° C. and the lower threshold for a temperaturethreshold may be about −15° C.

At block 1030, an updated environmental setpoint may be produced based,for example, on the measured power and/or the measured environmentalparameter. Following block 1025, the updated environmental setpoint maybe determined to bring the environment back within the upper thresholdvalue and the lower threshold value.

At block 1035 the updated environmental setpoint may be sent to the coldstorage facility system controller and/or one or more items ofequipment.

At block 1040 the power draw power level may be measured for the one ormore items of equipment in the facility such as, for example, asspecified in the power draw prescription. The power draw measurement,for example, may be received at the bypass controller from an externalsource and/or from an power sensor. The power draw measurement mayinclude the instantaneous power draw, an average power draw over apredetermined period of time, or any type of power draw measurement,etc.

At block 1045, if the power draw level is not at the prescribed level,then process 1000 proceeds to block 1030 and the environment setpointmay be adjusted to drive the power draw level lower.

If the power draw level is at the prescribed level, then process 1000proceeds to block 1050 where the environmental setpoint may be set atthe environmental value measured at block 1020. After block 1050,process 1000 may proceed back to block 1020.

FIG. 11 is a flowchart of a process 1100 for bypass control systemaccording to some embodiments. The process 1100 may include additionalblocks, some blocks may be skipped or may not be used, and/or the blocksmay occur in any order.

Process 1100 begins at block 1105. The bypass control system (e.g.,facility coordinator 115) may receive a power draw prescription. Thepower draw prescription, for example, may be received from a remoteserver such as, for example, from the scheduler 105. The power drawprescription, for example, may include a power level for one or moreitems of equipment in a facility such as, for example, a cold storagefacility. The power draw prescription, for example, may include a powerprofile that varies over time. The power draw prescription, for example,may include a power profile that is lower during times of high energydemand and/or high energy prices. The power draw prescription, forexample, may include a power profile that is higher during times of lowpower demand and/or low energy prices. The power draw prescription, forexample, may apply to all the items of equipment at a facility, a subsetof items of equipment, or one item of equipment at a facility.

At block 1110 one or more environmental parameters within the coldstorage facility and/or one or more of the items of equipment may bemeasured from one or more sensors. These sensors may include, forexample, a temperature sensor 170, a vessel pressure sensor 175, acondenser pressure sensor 180, a compressor oil pressure sensor 185, avessel level sensor 190, and/or other sensor 195.

At block 1115 the power draw power level may be measured for the one ormore items of equipment in the facility (or the entire facility) suchas, for example, as specified in the power draw prescription. The powerdraw measurement, for example, may be received at the bypass controllerfrom an external source and/or from an power sensor. The power drawmeasurement may include the instantaneous power draw, an average powerdraw over a predetermined period of time, or any type of power drawmeasurement, etc.

At block 1120, an environmental setpoint for one or more items ofequipment can be determined and/or created from a mathematical modelbased on the prescription, the measured power draw, and/or the measuredenvironmental parameters. The environmental setpoint, for example, mayinclude one or more of a temperature setpoint, a humidity setpoint, apressure setpoint, etc. The environmental setpoint, for example, may notinclude an energy setpoint or a power setpoint. The environmentalsetpoint, for example, may include a temperature setpoint for a cooler.The temperature of the cooler, for example, may be controlled by anumber of different items of equipment. The environmental setpoint maybe created based on one of various models of the items of equipmentand/or the facility that relate environmental parameters with powerconsumption.

At block 1125, if the bypass controller or the cold storage facilitysystem controller determines the measured environmental parameter is notwithin upper or lower threshold values, the process 1100 may proceed toblock 1130. If the bypass controller or the cold storage facility systemcontroller determines the measured environmental parameter is above ornear the upper threshold and/or below or near the lower threshold, theprocess 1100 may proceed to block 1135. In some embodiments, a singlethreshold may be used such as, for example, the upper temperaturethreshold.

For example, the upper threshold for a temperature threshold may beabout 0° C. and the lower threshold for a temperature threshold may beabout −20° C. As another example, the upper threshold for a temperaturethreshold may be about −5° C. and the lower threshold for a temperaturethreshold may be about −15° C.

At block 1130, an updated or revised environmental setpoint may beproduced. The updated environmental setpoint may be determined, forexample, to bring the environment back below or further below the upperthreshold value or above or further above the lower threshold value.After block 1130, process 1100 may proceed to block 1145. At block 1145the updated or revised environmental setpoint may be sent to the coldstorage facility system controller and/or one or more items ofequipment.

At block 1135, if the measured power draw level is not at the prescribedlevel, then process 1100 proceeds to block 1145. At block 1145 theenvironmental setpoint determined at block 1120 may be sent to the coldstorage facility system controller and/or one or more items ofequipment. At block 1135, if the measured power draw level is at theprescribed level, then the process 1100 proceeds to block 1140 and theenvironment setpoint is set to the measured environmental parameter. Atblock 1145 the environmental setpoint may be sent to the cold storagefacility system controller and/or one or more items of equipment.

The computational system 1200, shown in FIG. 12 can be used to performany of the embodiments of the invention. As another example,computational system 1200 can be used perform any calculation,identification and/or determination described in this document such as,for example, process 1000 or process 1100. Computational system 1200includes hardware elements that can be electrically coupled via a bus1205 (or may otherwise be in communication, as appropriate). Thehardware elements can include one or more processors 1210, includingwithout limitation one or more general-purpose processors and/or one ormore special-purpose processors (such as digital signal processingchips, graphics acceleration chips, and/or the like); one or more inputdevices 1215, which can include without limitation a mouse, a keyboardand/or the like; and one or more output devices 1220, which can includewithout limitation a display device, a printer and/or the like.

The computational system 1200 may further include (and/or be incommunication with) one or more storage devices 1225, which can include,without limitation, local and/or network accessible storage and/or caninclude, without limitation, a disk drive, a drive array, an opticalstorage device, a solid-state storage device, such as a random accessmemory (“RAM”) and/or a read-only memory (“ROM”), which can beprogrammable, flash-updateable and/or the like. The computational system1200 might also include a communications subsystem 1230, which caninclude without limitation a modem, a network card (wireless or wired),an infrared communication device, a wireless communication device and/orchipset (such as a Bluetooth device, an 802.6 device, a Wi-Fi device, aWiMax device, cellular communication facilities, etc.), and/or the like.The communications subsystem 1230 may permit data to be exchanged with anetwork (such as the network described below, to name one example),and/or any other devices described herein. In many embodiments, thecomputational system 1200 will further include a working memory 1235,which can include a RAM or ROM device, as described above.

The computational system 1200 also can include software elements, shownas being currently located within the working memory 1235, including anoperating system 1240 and/or other code, such as one or more applicationprograms 1245, which may include computer programs of the invention,and/or may be designed to implement methods of the invention and/orconfigure systems of the invention, as described herein. For example,one or more procedures described with respect to the method(s) discussedabove might be implemented as code and/or instructions executable by acomputer (and/or a processor within a computer). A set of theseinstructions and/or codes might be stored on a computer-readable storagemedium, such as the storage device(s) 1225 described above.

In some cases, the storage medium might be incorporated within thecomputational system 1200 or in communication with the computationalsystem 1200. In other embodiments, the storage medium might be separatefrom a computational system 1200 (e.g., a removable medium, such as acompact disc, etc.), and/or provided in an installation package, suchthat the storage medium can be used to program a general-purposecomputer with the instructions/code stored thereon. These instructionsmight take the form of executable code, which is executable by thecomputational system 1200 and/or might take the form of source and/orinstallable code, which, upon compilation and/or installation on thecomputational system 1200 (e.g., using any of a variety of generallyavailable compilers, installation programs, compression/decompressionutilities, etc.) then takes the form of executable code.

Unless otherwise specified, the term “substantially” means within 5% or10% of the value referred to or within manufacturing tolerances. Unlessotherwise specified, the term “about” means within 5% or 10% of thevalue referred to or within manufacturing tolerances.

The conjunction “or” is inclusive.

Numerous specific details are set forth herein to provide a thoroughunderstanding of the claimed subject matter. However, those skilled inthe art will understand that the claimed subject matter may be practicedwithout these specific details. In other instances, methods, apparatusesor systems that would be known by one of ordinary skill have not beendescribed in detail so as not to obscure claimed subject matter.

Some portions are presented in terms of algorithms or symbolicrepresentations of operations on data bits or binary digital signalsstored within a computing system memory, such as a computer memory.These algorithmic descriptions or representations are examples oftechniques used by those of ordinary skill in the data processing artsto convey the substance of their work to others skilled in the art. Analgorithm is a self-consistent sequence of operations or similarprocessing leading to a desired result. In this context, operations orprocessing involves physical manipulation of physical quantities.Typically, although not necessarily, such quantities may take the formof electrical or magnetic signals capable of being stored, transferred,combined, compared or otherwise manipulated. It has proven convenient attimes, principally for reasons of common usage, to refer to such signalsas bits, data, values, elements, symbols, characters, terms, numbers,numerals or the like. It should be understood, however, that all ofthese and similar terms are to be associated with appropriate physicalquantities and are merely convenient labels. Unless specifically statedotherwise, it is appreciated that throughout this specificationdiscussions utilizing terms such as “processing,” “computing,”“calculating,” “determining,” and “identifying” or the like refer toactions or processes of a computing device, such as one or morecomputers or a similar electronic computing device or devices, thatmanipulate or transform data represented as physical electronic ormagnetic quantities within memories, registers, or other informationstorage devices, transmission devices, or display devices of thecomputing platform.

The system or systems discussed herein are not limited to any particularhardware architecture or configuration. A computing device can includeany suitable arrangement of components that provides a resultconditioned on one or more inputs. Suitable computing devices includemultipurpose microprocessor-based computer systems accessing storedsoftware that programs or configures the computing system from ageneral-purpose computing apparatus to a specialized computing apparatusimplementing one or more embodiments of the present subject matter. Anysuitable programming, scripting, or other type of language orcombinations of languages may be used to implement the teachingscontained herein in software to be used in programming or configuring acomputing device.

Embodiments of the methods disclosed herein may be performed in theoperation of such computing devices. The order of the blocks presentedin the examples above can be varied—for example, blocks can bere-ordered, combined, and/or broken into sub-blocks. Certain blocks orprocesses can be performed in parallel.

The use of “adapted to” or “configured to” herein is meant as open andinclusive language that does not foreclose devices adapted to orconfigured to perform additional tasks or steps. Additionally, the useof “based on” is meant to be open and inclusive, in that a process,step, calculation, or other action “based on” one or more recitedconditions or values may, in practice, be based on additional conditionsor values beyond those recited. Headings, lists, and numbering includedherein are for ease of explanation only and are not meant to belimiting.

While the present subject matter has been described in detail withrespect to specific embodiments thereof, it will be appreciated thatthose skilled in the art, upon attaining an understanding of theforegoing, may readily produce alterations to, variations of, andequivalents to such embodiments. Accordingly, it should be understoodthat the present disclosure has been presented for purposes of examplerather than limitation, and does not preclude inclusion of suchmodifications, variations and/or additions to the present subject matteras would be readily apparent to one of ordinary skill in the art.

That which is claimed:
 1. A system for controlling cold storageequipment at an industrial cold storage facility, the system comprising:a cloud scheduler located in a location remote from the industrial coldstorage facility, the cloud scheduler creates a power draw prescriptionfor one or more items of cold storage equipment at an industrial coldstorage facility, and the cloud scheduler communicates the power drawprescription to the cold storage facility, the power draw prescriptionincludes a desired power draw level for one or more items of coldstorage equipment at the industrial cold storage facility, and thedesired power draw level changes over a period of time; and a bypasscontroller located at the industrial cold storage facility that receivesa power draw prescription from the cloud scheduler, produces anenvironmental setpoint for the one or more items of equipment, andoutputs the environmental setpoint to a device controller or a systemcontroller.
 2. The system according to claim 1, wherein the one or moreitems of cold storage equipment comprises one or more of a motor, avalve, a vessel, an evaporator, a condenser, a pump, a compressor, adoor, an underfloor heating element, a light, defrost equipment, acentrifuge, and/or a furnace.
 3. The system according to claim 1, wherethe bypass controller receives temperature data from a temperaturesensor at the portion of the cold storage facility; determines whetherthe temperature data has exceeded or is approaching a thresholdtemperature value for the portion of the cold storage facility; and inthe event the temperature data has exceeded or is approaching athreshold temperature value: produces a second temperature setpoint; andcommunicates the second temperature setpoint to the system controller.4. The system according to claim 1, wherein the system controller or thedevice controller comprises a PID controller.
 5. The system according toclaim 1, wherein the environmental setpoint comprises a setpoint thatdoes not include an energy setpoint or a power setpoint.
 6. The systemaccording to claim 1, wherein the device controller or the systemcontroller controls the one or more items of equipment at the industrialcold storage facility.
 7. The system according to claim 1, wherein theenvironmental setpoint changes over a period of time.
 8. A methodcomprising: receiving, at a bypass controller at an industrial coldstorage facility, a power draw prescription from a remote server, thepower draw prescription includes a desired power draw level for one ormore items of cold storage equipment at the industrial cold storagefacility, and the desired power draw level changes over a period oftime; converting, at the bypass controller, the power draw prescriptionto a temperature setpoint for a portion of the cold storage facilitybased on a mathematical model of the one or more items of cold storageequipment; and communicating the temperature setpoint to a cold storagefacility system controller that is coupled with the one or more items ofcold storage equipment.
 9. The method according to claim 8, wherein theone or more items of cold storage equipment comprises one or more of amotor, a valve, a vessel, an evaporator, a condenser, a pump, acompressor, a door, an underfloor heating element, a light, defrostequipment, a centrifuge, and/or a furnace.
 10. The method according toclaim 8, further comprising: receiving, at the bypass controller,temperature data from a temperature sensor at the portion of the coldstorage facility; determining, at the bypass controller, whether thetemperature data has exceeded or is approaching a threshold temperaturevalue for the portion of the cold storage facility; and in the event thetemperature data has exceeded or is approaching a threshold temperaturevalue: producing a second temperature setpoint; and communicating thesecond temperature setpoint to the system controller.
 11. The methodaccording to claim 8, further comprising: receiving, at the cold storagefacility system controller, temperature data from a temperature sensorat the portion of the cold storage facility; determining, at the coldstorage facility system controller, whether the temperature data hasexceeded or is approaching a threshold temperature value for the portionof the cold storage facility; and in the event the temperature data hasexceeded or is approaching a threshold temperature value: producing asecond temperature setpoint; and communicating the second temperaturesetpoint to the system controller.
 12. The method according to claim 8,wherein the power draw prescription varies based on utility prices. 13.The method according to claim 8, wherein the cold storage facilitysystem controller comprises a PID controller.
 14. A non-transitorycomputer readable medium having instructions stored thereon forperforming a method of: receiving, at a bypass controller at anindustrial cold storage facility, a power draw prescription from aremote server, the power draw prescription includes a desired power drawlevel for one or more items of cold storage equipment at the industrialcold storage facility, and the desired power draw level changes over aperiod of time; converting, at the bypass controller, the power drawprescription to a temperature setpoint for a portion of the cold storagefacility based on a mathematical model of the one or more items of coldstorage equipment; and communicating the temperature setpoint to a coldstorage facility system controller that is coupled with the one or moreitems of cold storage equipment.
 15. The non-transitory computerreadable medium according to claim 14, wherein the one or more items ofcold storage equipment comprises one or more of a motor, a valve, avessel, an evaporator, a condenser, a pump, a compressor, a door, anunderfloor heating element, a light, defrost equipment, a centrifuge,and/or a furnace.
 16. The non-transitory computer readable mediumaccording to claim 14, wherein the computer readable medium furtherincludes instructions for: receiving, at the bypass controller,temperature data from a temperature sensor at the portion of the coldstorage facility; determining, at the bypass controller, whether thetemperature data has exceeded or is approaching a threshold temperaturevalue for the portion of the cold storage facility; and in the event thetemperature data has exceeded or is approaching a threshold temperaturevalue: producing a second temperature setpoint; and communicating thesecond temperature setpoint to the system controller.
 17. A bypasscontroller in communication with a cloud controller and a devicecontroller at an industrial cold storage facility, the bypass controllercomprising: a transceiver that receives data from a cloud schedulerlocated in a location remote from the industrial cold storage facility;and a processor that: receives a power draw prescription for one or moreitems of cold storage equipment at the industrial cold storage facility,the power draw prescription includes a desired power draw level for oneor more items of cold storage equipment at the industrial cold storagefacility, and the desired power draw level changes over a period oftime; produces an environmental setpoint for the one or more items ofequipment; and outputs the environmental setpoint to a device controlleror a system controller.
 18. The bypass controller according to claim 17,wherein the processor outputs the environmental setpoint via thetransceiver.
 19. The bypass controller according to claim 17, whereinthe processor outputs the environmental setpoint via an output that isseparate and distinct from the transceiver.